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Introduction to

Finite Element Analysis Using SolidWorks Simulation 2013 ®

Randy H. Shih

SDC

P U B L I C AT I O N S

Schroff Development Corporation

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Introduction to Finite Element Analysis

Table of Contents Preface Acknowledgments

i ii

Introduction Introduction Development of Finite Element Analysis FEA Modeling Considerations Types of Finite Elements Finite Element Analysis Procedure Matrix Definitions Getting Started with SolidWorks Starting SolidWorks Units Setup SolidWorks Screen Layout • Menu Bar Toolbar • Menu Bar Pull-down Menus • Heads-up View Toolbar • Features Toolbar • Sketch Toolbar • Command Manager • Feature Manager Design Tree • Graphics Area • Reference Triad • Origin • Confirmation Corner • Graphics Cursor or Crosshairs • Message and Status Bar Basic Functions of Mouse Buttons [Esc] – Canceling Commands On-Line Help Leaving SolidWorks Creating a CAD Files Folder

Intro-2 Intro-2 Intro-3 Intro-4 Intro-6 Intro-6 Intro-9 Intro-9 Intro-11 Intro-13 Intro-13 Intro-14 Intro-14 Intro-14 Intro-14 Intro-15 Intro-16 Intro-17 Intro-17 Intro-17 Intro-17 Intro-17 Intro-17 Intro-18 Intro-18 Intro-19 Intro-19 Intro-20

Chapter 1

The Direct Stiffness Method Introduction One-dimensional Truss Element Example 1.1 Example 1.2

1-2 1-3 1-5 1-7

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Introduction to Finite Element Analysis

Basic Solid Modeling using SolidWorks The Adjuster Design Starting SolidWorks Step 1: Creating a Rough Sketch Graphics Cursors Geometric Relation Symbols Step 2: Apply/Modify Relations and Dimensions Changing the Dimension Standard Viewing Functions – Zoom and Pan Modifying the Dimensions of the Sketch Step 3: Completing the Base Solid Feature Isometric View Rotation of the 3D Model – Rotate View Rotation and Panning – Arrow Keys Dynamic Viewing – Quick Keys Viewing Tools – Heads-up View Toolbar View Orientation Display Style Orthographic vs. Perspective Customizing the Heads-up View Toolbar Sketch Plane Step 4-1: Adding an Extruded Boss Feature Step 4-2: Adding an Extruded Cut Feature Save the Part and Exit Questions Exercises

1-10 1-10 1-10 1-12 1-12 1-14 1-15 1-16 1-17 1-18 1-19 1-20 1-20 1-22 1-23 1-25 1-26 1-27 1-27 1-27 1-28 1-30 1-33 1-35 1-36 1-37

Chapter 2

Truss Elements in Two-Dimensional Spaces Introduction Truss Elements in Two-Dimensional Spaces Coordinate Transformation EXAMPLE 2.1 Solution Global Stiffness Matrix EXAMPLE 2.2 Solution Questions Exercises

2-2 2-2 2-5 2-9 2-10 2-10 2-13 2-13 2-19 2-20

Table of Contents

Chapter 3

2D Trusses in MS Excel and Truss Solver Direct Stiffness Matrix Method using Excel EXAMPLE 3.1 Establish the Global K Matrix for each Member Assembly of the Overall Global Stiffness Matrix Solving the Global Displacements Calculating Reaction Forces Determining the Stresses in Elements The Truss Solver and the Truss View Programs The Truss View Program Questions Exercises

3-2 3-2 3-3 3-8 3-10 3-16 3-18 3-23 3-30 3-32 3-33

Chapter 4

Truss Elements in SolidWorks Simulation One-dimensional Line Elements Starting SolidWorks Units Setup Creating the CAD Model – Solid Modeling Approach A CAD Model is NOT an FEA Model The SolidWorks Simulation Module Creating an FEA Model Assign the Element Material Property Applying Boundary Conditions - Constraints Applying External Loads Create the FEA Mesh and Run the Solver Viewing the Stress Results Viewing the Displacement Results Questions Exercises

4-2 4-4 4-5 4-6 4-15 4-16 4-17 4-19 4-20 4-23 4-25 4-26 4-28 4-29 4-30

Chapter 5

SolidWorks Simulation Two-Dimensional Truss Analysis Finite Element Analysis Procedure Preliminary Analysis Starting SolidWorks Units Setup Creating the CAD Model – Structural Member Approach Creating Structural Members in SolidWorks Weldment Profiles Activate the SolidWorks Simulation Module Setting Up Truss Elements

5-2 5-3 5-4 5-5 5-6 5-8 5-9 5-12 5-14

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Introduction to Finite Element Analysis

Assign the Element Material Property Applying Boundary Conditions - Constraints and Loads Applying External Loads Create the FEA Mesh and Run the Solver Viewing the Stress results Viewing the Internal Loads of All members Viewing the Reaction Forces at the supports Questions Exercises

5-15 5-16 5-21 5-23 5-24 5-26 5-27 5-28 5-29

Chapter 6

Three-Dimensional Truss Analysis Three-Dimensional Coordinate Transformation Matrix Stiffness Matrix Degrees of Freedom Problem Statement Preliminary Analysis Starting SolidWorks Units Setup Creating the CAD Model – Structural Member Approach Creating Weldments Profiles in SolidWorks Creating Structural Members using the New Profile Editing the Dimensions of the New Profile Activate the SolidWorks Simulation Module Setting Up Truss Elements Assign the Element Material Property Applying Boundary Conditions - Constraints Applying External Loads Create the FEA Mesh and Run the Solver Using the Probe Option to View Individual Stress Viewing the Internal Loads of All Members Questions Exercises

6-2 6-3 6-3 6-5 6-5 6-7 6-8 6-9 6-12 6-16 6-18 6-19 6-21 6-22 6-23 6-24 6-26 6-27 6-28 6-29 6-30

Chapter 7

Basic Beam Analysis Introduction Modeling Considerations Problem Statement Preliminary Analysis Starting SolidWorks Units Setup

7-2 7-2 7-3 7-3 7-6 7-7

Table of Contents

Creating the CAD Model – Structural Member Approach Creating a Rectangular Weldment Profile Creating Structural Members using the New Profile Adjusting the Orientation of the Profile Adding a Datum Point for the Concentrated Load Activate the SolidWorks Simulation Module Assign the Element Material Property Applying Boundary Conditions - Constraints Applying Concentrated Point Loads Applying the Distributed Load Create the FEA Mesh and Run the Solver What Went Wrong? Directions 1 and 2 in Shear and Moment Diagrams Questions Exercises

7-8 7-10 7-14 7-15 7-16 7-18 7-20 7-21 7-24 7-26 7-28 7-29 7-32 7-34 7-35

Chapter 8

Beam Analysis Tools Introduction Problem Statement Preliminary Analysis Stress Components Starting SolidWorks Creating the CAD Model – Structural Member Approach Creating a Rectangular Weldment Profile Creating Structural Members using the New Profile Adjusting the Orientation of the Profile Adding a Datum Point Activate the SolidWorks Simulation Module Assign the Element Material Property Applying Boundary Conditions - Constraints Applying the Distributed Load Create the FEA Mesh and Run the Solver Shear and Moment Diagrams Using the Probe Option to Examine Stress at Point1 Questions Exercises

8-2 8-2 8-3 8-4 8-6 8-7 8-9 8-13 8-14 8-15 8-17 8-19 8-20 8-23 8-25 8-26 8-28 8-29 8-30

Chapter 9

Statically Indeterminate Structures Introduction Problem Statement

9-2 9-3

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Introduction to Finite Element Analysis

Preliminary Analysis Starting SolidWorks Creating the CAD Model Creating a Circular Weldment Profile Creating Structural Members using the New Profile Adding a Datum Point for the Concentrated Load Activate the SolidWorks Simulation Module Assign the Element Material Property Applying Boundary Conditions - Constraints Applying the Concentrated Point Load Create the FEA Mesh and Run the Solver Viewing the Internal Loads of All members Shear and Moment Diagrams Questions Exercises

9-3 9-6 9-7 9-9 9-13 9-14 9-16 9-18 9-19 9-23 9-24 9-25 9-26 9-28 9-29

Chapter 10

Two-Dimensional Surface Analysis Introduction Problem Statement Preliminary Analysis • Maximum Normal Stress • Maximum Displacement Geometric Considerations of Finite Elements Starting SolidWorks Creating a CAD Model in SolidWorks Activate the SolidWorks Simulation Module Defining a Surface Model Assign the Element Material Property Applying Boundary Conditions - Constraints Applying the External Load H-Element versus P-Element Create the first 2D Mesh –Coarse Mesh Run the Solver Refinement of the Mesh– Global Element Size 0.10 Refinement of the Mesh– Global Element Size 0.05 Refinement of the Mesh– Global Element Size 0.03 Refinement of the Mesh– Global Element Size 0.02 Comparison of Results Questions Exercises

10-2 10-3 10-3 10-3 10-4 10-5 10-6 10-7 10-10 10-12 10-13 10-14 10-17 10-20 10-21 10-23 10-25 10-27 10-29 10-30 10-31 10-32 10-33

Table of Contents

Chapter 11

Three-Dimensional Solid Elements Introduction Problem Statement Preliminary Analysis Starting SolidWorks Creating a CAD Model in SolidWorks  Define the Sweep Path  Define the Sweep Section  Create the Swept Feature  Create a Cut Feature Activate the SolidWorks Simulation Module Assign the Element Material Property Applying Boundary Conditions - Constraints Applying the External Load Create the first FEA Mesh –Coarse Mesh Run the Solver Refinement of the Mesh– Global Element Size 0.10 Refinement of the FEA Mesh – Mesh Control Option Refinement of the FEA Mesh – Automatic Transition Comparison of Results Notes on FEA Linear Static Analyses Questions Exercises

11-2 11-3 11-4 11-7 11-8 11-8 11-10 11-12 11-13 11-15 11-17 11-18 11-19 11-20 11-22 11-24 11-26 11-29 11-31 11-32 11-33 11-34

Chapter 12

3D Thin Shell Analysis Introduction Problem Statement Preliminary Analysis Starting SolidWorks Creating a CAD Model in SolidWorks Activate the SolidWorks Simulation Module Assign the Element Material Property Applying Boundary Conditions - Constraints Applying the External Pressure Create the first FEA Mesh –Coarse Mesh Run the Solver and View the Results Refinement of the Mesh– Global Element Size 0.0125 Starting a New 3D Surface Model Starting a New FEA Study Completing the Definition of the Surface Model Assign the Element Material Property

12-2 12-4 12-4 12-6 12-7 12-9 12-11 12-12 12-14 12-15 12-16 12-17 12-18 12-21 12-22 12-23

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Introduction to Finite Element Analysis

Applying Boundary Conditions - Constraints Applying the External Pressure Create the first FEA Mesh –Coarse Mesh Run the Solver and View the Results Refinement of the Mesh– Global Element Size 0.010 Questions Exercises

12-24 12-28 12-29 12-30 12-31 12-32 12-33

Chapter 13

Dynamic Modal Analysis Introduction Problem Statement Preliminary Analysis The Cantilever Beam Modal Analysis Program Starting SolidWorks Creating a CAD Model in SolidWorks Activate the SolidWorks Simulation Module Assign the Element Material Property Create the first FEA Mesh View the Results Refinement of the Mesh– Global Element Size 0.15 Adding an Additional Mass to the System One-Dimensional Beam Frequency Analysis Conclusions Questions Exercises

Index

13-2 13-3 13-3 13-6 13-9 13-10 13-12 13-15 13-16 13-18 13-21 13-23 13-27 13-28 13-29 13-30